Closure flap

ABSTRACT

A closure flap ( 11 ) in an outer wall of a vehicle, in particular a coach, for closing an opening in a vehicle, containing a flap element ( 1 ) and a reinforcing structure on the flap element ( 1 ). A reinforcing structure on the flap element ( 1 ) comprises adhesively bonded corner elements ( 2   a,    2   b,    2   c,    2   d ) which are joined together via longitudinal section parts ( 3   a,    3   b,    3   c,    3   d ) to form a frame-type structure.

BACKGROUND OF THE INVENTION

The present invention relates to a closure flap containing a flap element and a reinforcing structure on the flap element. The invention also relates to a process for manufacturing the closure flap and the use of the closure flap.

Closure flaps on the outside of omnibuses or coaches for closing off openings e.g. to a luggage hold, are known. As a rule, the closure flaps contain a flap-type element made of sheet or a panel which is shaped to match the outer contour of the vehicle, and on the inside i.e. facing the interior of the vehicle and attached to the flap element, a reinforcing frame for increasing the torsional rigidity of the closure flap.

Up to now, the reinforcing frame has been manufactured in separate assembly steps and mounted and joined to the flap element as a complete frame. The production of such closure flaps is for that reason rather involved and costly.

The object of the invention is therefore to propose a stable, torsion-rigid closure flap which is cost favourable to manufacture and involves as few as possible assembly steps.

SUMMARY OF THE INVENTION

The object is achieved by way of the invention in that the reinforcing structure comprises individual frame elements on the closure flap which are joined together to form a frame-type structure. The frame elements preferably contain corner elements and longitudinal section parts and as necessary a reinforcing section, in particular a so-called lock traverse.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention is described in greater detail by way of examples and with reference to the accompanying drawings. These show in:

FIG. 1: a perspective view of a closure flap;

FIG. 2 a-d: a representation of the individual assembly steps;

FIG. 3: a perspective view of a panel element;

FIG. 4: cross-section X-X through the closure flap shown in FIG. 1.

DETAILED DESCRIPTION

The corner elements are preferably joined to the flap element via a large area adhesive joint i.e. adhesively bonded to it. The section parts are likewise preferably joined to the corner elements via a large area adhesive joint. Further, the section parts may also be joined to the flap element via a large area adhesive joint.

The adhesive is preferably a heat-resistant adhesive. The adhesive joint between the different frame elements and to the flap element is in particular preferably made using a reaction type adhesive. This may be e.g. an epoxy, acrylic or polyurethane adhesive.

The flap element is preferably of a multi-layer panel material, in particular a sandwich panel containing a core layer and outer layers on both sides of the core layer. The core layer may be of a plastic e.g. a porous plastic or foam. The outer layers may be of metal e.g. sheet such as steel or aluminium or an aluminium alloy or of plastic panels e.g. fibre-reinforced plastic panels.

The multi-layer panel material is characterised—in comparison with conventional sheet elements—by a higher resistance to bending and torsional forces.

The panel element is in particular preferably made of a composite panel comprising a web-shaped core with outer layers on both sides which are joined to the core by adhesive bonding. One or both outer layers are preferably covering sheets of a metal e.g. of steel and in particular aluminium or an aluminium alloy. The web-shaped core may likewise be of a metal e.g. of steel and in particular aluminium or an aluminium alloy.

The web-shaped core and in particular the outer layers may also be of a plastic. The outer layers may e.g. be of a fibre-reinforced plastic.

The flap element may be e.g. 3-10 mm thick, in particular 5-7 mm thick. The panel element may be e.g. 0.5-2 m broad, in particular 0.8-1.5 m broad and 0.5-3 m long, in particular 1.0-1.7 m long.

The corner elements are preferably in the form of corner angles and contain a first corner element wall which runs parallel to the panel surface and rests against this, and also a second corner element wall which lies at an angle, preferably a right angle, to the first corner element wall and projects out from the panel surface. The second element wall also exhibits a corresponding bend, preferably of 90°, to form the corner angle.

The corner angles are highly preferably U-shaped in cross-section and contain a third corner element wall which runs a distance from and parallel to the first corner element wall, whereby the second corner element wall joins the first and third corner element wall.

The corner elements may be made of a metal e.g. steel and in particular aluminium or an aluminium alloy. Further, the corner elements may also be made of a plastic, in particular a fibre-reinforced plastic.

The corner elements may e.g. be of a rolled product such as sheet, or an extruded product. Further, the corner elements may also be a casting.

The section parts may be in the form of open or hollow extrusions. The extruded parts are preferably in the form of open sections, preferably profiled strips, in particular angular strips.

The section parts preferably form at least two section walls, whereby a first section wall runs parallel to the panel surface and rests against it. A second section wall lies at an angle, in particular at a right angle to the first section wall and projects out from the panel surface.

In a highly preferred is a version of the invention the section parts are in the form of Z-shaped sections containing two facing first and third section walls running parallel to the panel surface and a second section wall projecting out from the panel surface and lying at an angle—preferably a right angle—to and joining the first and third section walls.

Additionally, the section parts may also be in the form of a U-shaped section with a flange lying on the panel surface.

The section parts may be made of metal e.g. steel and in particular aluminium or an aluminium alloy. Further, the section parts may also be made of a plastic, in particular a fibre-reinforced plastic. The section parts may e.g. be made out of a bent product e.g. a bent rolled section. This may e.g. be a bent sheet. In a preferred version of the invention the section parts are, however, extruded products.

The large area adhesive joint between profile section and corner element is preferably made between the second section wall and the second corner element wall. The second joint may also be made between the second and third section walls. Further, the components may also be joined to each other via both joint faces.

The corner elements and section parts are, according to an especially preferred configuration, fitted together to a rectangular shaped frame, whereby a corner element is situated at each corner of the frame.

The frame serves to stiffen the closure flap, in particular to increase the torsional rigidity, and as a point for attaching various functional elements.

Such functional elements may be e.g. a reinforcing section which e.g. is in the form of a lock traverse, a cladding element, a hinge-type joint or an opening and closing mechanism with alignment elements such as guide rails, rails, slides, spring supports or telescoping rods. Additionally one may provide or make provision for attachment parts on the frame-type structure e.g. joints or also openings such as holes.

If the closure flap according to the invention is employed as a tiltable flap, then a section part of the frame-type structure, in particular a section wall of this section part running parallel to the panel surface, preferably contains a structural connecting means for a rotational hinge joint, in particular for a hinge. The joint structure also contains passages, preferably ring-shaped in cross-section, to accommodate a hinge pin.

In a preferred further development of the invention provision is made for aids to positioning and aligning frame elements in a specific position on the flap element. As a rule not all frame elements require positioning aids to be attached to the flap elements. It is therefore adequate e.g. if individual, several or all corner elements are attached to the flap elements in a predefined position. The section parts in turn are then aligned positioned and attached via the section parts. Of course individual, several or all section parts may also be attached to the flap element by means of positioning aids. The corner elements in turn may then be positioned and attached via the section parts.

It is also possible to attach all frame elements on the flap element via positioning aids, also if this is not absolutely essential. For reasons of costs and time, however, only as many frame elements are arranged on the flap element as is necessary, this in order to mount the whole frame-type structure in a predefined position on the flap element without additional positioning aids.

In a further development of the invention the flap element preferably contains openings, in particular openings to accommodate the above mentioned positioning aids.

The positioning aids preferably contain pin-shaped bodies which are introduced into openings, in particular bored holes in the frame elements, in particular in the corner elements, this with a view to aligning the frame elements. The openings or holes are preferably provided in the first wall elements resting on the flap element, for example corner elements or section parts.

In a preferred version of the invention the positioning aids are inserted into the recesses or holes in the flap element and, on mounting the frame elements, engage with the same to align them on the flap element by means of their pin-shaped bodies passing through the openings or holes in the frame element, in particular in the corner elements.

According to an alternative version of the invention the positioning aids are mount-ed on the frame elements, in particular on the corner elements, and on mounting the frame elements on the flap element engage on the same for the purpose of positioning them with their end parts engaging in the recesses or holes in the panel element.

The holes in the flap element and/or in the frame elements may be threaded holes, whereby the positioning aids are accordingly screwed in. The positioning aids are, however, preferably pushed through or into the said recesses or holes. The positioning aids may be adhesively bonded in the recesses in the flap element or in the frame element, or anchored there by virtue of a specific geometric arrangement.

In a preferred version of the invention the positioning aids contain a head part by means of which these are inserted into the recesses in the flap element, whereby the head part has a larger cross-section than the opening in the frame element.

The head part preferably projects out to a certain degree beyond the surface of the flap element, thus forming a contact face for the adjacent wall of the frame element, thus acting as a spacer between the frame element and the flap element. The space formed between the two elements defines the adhesive space or thickness of the adhesive layer.

In an alternative version of the invention the positioning aids are provided between the frame element and flap element with washers or spacer rings. The washers or spacer rings act here as spacer elements.

The positioning aids may be conceived such that these are either permanently integrated in the frame-type structure, or are removed again after the positioning and attachment of the frame elements.

The above mentioned positioning aids may be of metal or plastic. They preferably only serve the purpose of positioning and alignment of the functional element in question and not the connection of the same to the panel element.

In the further development of the invention the frame elements also encompass a reinforcing section which e.g. may be present in a version including a so called lock traverse for attaching a lock. The reinforcing section usefully runs within the reinforcing frame, parallel to one of the sides of the frame. The reinforcing section preferably features a section, which is hat-shaped in cross-section, and two section walls at the side which run parallel to and contact the panel surface. The reinforcing section is joined to the panel surface, preferably e.g. via a large area adhesive joint.

The reinforcing section is also preferably joined to the neighbouring section parts of the frame structure via a large area adhesive joint.

The reinforcing section may be made of a plastic, in particular a fibre-reinforced plastic or metal e.g. steel and in particular of aluminium or an aluminium alloy. The reinforcing section is preferably made from sheet bent into shape.

The reinforcing section may also be attached by means of the positioning aids described above in detail, whereby all of the above described versions may be used in also conjunction with the reinforcing section.

The closure flap finds application in particular or on vehicles for transportation of people or goods, in particular in or on mass-transportation means for transporting people or goods. Such mass-transportation means may be: railway vehicles, road vehicles such as lorries, buses, in particular omnibuses or coaches, aeroplanes or boats. The closure flap according to the invention may also find application both in the interior and in the exterior regions, in particular in vertical outer walls, of the above mentioned vehicles.

The closure flap according to the invention may also be employed in architectural applications such as e.g. in buildings or in interior design applications and in furniture manufacture.

The closure flap finds application in the closure of storage rooms such as e.g. luggage storage space, for closing openings which ensure access to technical facilities, for closure of entry or exit places, and for closing openings for loading or unloading.

The closure flap according to the invention finds preferable application in the outer walls of a bus, in particular an omnibus or coach for closure of storage space, in particular luggage storage space.

The closure flap according to the invention may e.g. be employed as a jacking flap which does not require a hinge, or as a tilting flap.

The invention also relates to a process for manufacturing a closure flap of the kind described above.

The process is characterised by way of the following manufacturing steps:

-   preparing a flap element; -   mounting and positioning the individual frame elements on the flap     element; -   adhesively bonding the frame elements to the flap element and/or to     the neighbouring frame elements to create a frame-type structure.

A further development of the process is characterised by the following steps:

-   preparation of a flap element; -   mounting and positioning the corner elements on the flap element; -   adhesively bonding the corner elements to the flap element; -   mounting and positioning the section parts; -   adhesively bonding the section parts to the corner elements and/or     the flap element.

In a further development of the invention the following additional steps may be included:

-   mounting and positioning a reinforcing section, in particular a lock     traverse, on the flap element; -   adhesively bonding the reinforcing section to the flap element     and/or the section parts.

The reinforcing section is preferably mounted on the flap element before the section parts, positioned there and adhesively bonded to it. The reinforcing section may be mounted on the flap element together with the corner elements or after the corner elements, positioned and adhesively bonded. In a preferred version of the invention the section parts engage over the section parts by means of their third side.

In a preferred version of the process, openings, in particular bored holes, are introduced into the flap element before mounting the reinforcing frame. The recesses or holes serve the purpose of introducing positioning aids for alignment and attachment of frame elements, in particular the corner elements and if desired a reinforcing section. This step may take place along with cutting the panel material into flap elements.

Subsequent to the above process step the recesses or holes are fitted with positioning aids.

The creation of the holes and the fitting of the panel element with positioning aids take place preferably automatically. This process is comparable with the preparation of boards for the production of printed circuits.

For the positioning of the frame elements, in particular the corner elements or the reinforcing section, the frame elements are mounted on the flap element and brought into the predefined position, whereby the positioning aids are introduced into openings in the frame elements. The frame elements which are brought into the predefined position on the flap element by means of the positioning aids are then adhesively bonded to the flap element.

In an alternative embodiment the frame elements, in particular the corner elements and if desired the reinforcing section, is fitted with the positioning aids. The frame elements fitted with positioning aids are mounted onto the flap element, whereby the positioning aids engage in the intended recesses in the flap element.

After the frame elements, that have been mounted on the flap element by means of positioning aids, have been fixed in place, those frame elements, in particular the section parts, that could be mounted without the above mentioned positioning aids, are mounted onto the flap element, preferably using adhesive bonding, fixed to the flap element and/or on the already attached frame elements, whereby the last mentioned frame elements are aligned with respect to the frame elements that have already been fixed in place.

The manner of construction described above is characterised by way of the advantage that the reinforcing frame no longer requires to be prefabricated, but instead can be assembled at the same time as the individual frame elements are mounted on the panel element. The panel element serves as an assembly aid and the positioning aids replace the jigging devices for fitting the frame together. Assembly devices for the production of the reinforcing frame are therefore unnecessary, whereby a higher degree of flexibility is achieved in the production of closure flaps with reinforcing frames of different size.

The greater degree of stiffness in the multilayer flap element simplifies the assembly process further in that the flap element itself does not have to be supported.

As a result of the construction according to the invention the preliminary assembly of the frame is eliminated, which produces considerable savings in terms of time and costs. Further, the production of the recesses in the flap element and the fitting of the positioning aids can be performed completely automatically, resulting in an additional increase in efficiency.

The closure flap 11 contains a panel element 1, preferably made of a sandwich material, in particular a sandwich material as shown in FIG. 3. Mounted on the side of the panel element 1 facing the interior of the vehicle is a frame structure comprising four corner angle pieces 2 a, 2 b, 2 c, 2 d each of which, via positioning aids 8 a, 8 d, is mounted on the panel element 1, aligned and joined to it by means of an adhesive joint. The corner angle pieces 2 a, 2 b, 2 c, 2 d are joined together via section strips 3 a, 3 b, 3 c, 3 d to form a rectangular frame-type structure. The section strips 3 a, 3 b, 3 c, 3 d contain first section walls which run parallel to the panel surface and make contact with it, and second section walls which are lie at a right angle to the first section wall and are a distance from the panel surface.

The section strips 3 a, 3 b, 3 c, 3 d are preferably joined to the corner angel pieces 2 a, 2 b, 2 c, 2 d via an adhesive joint. To that end, the two section walls of the section strip are adhesive bonded to second corner element walls which run parallel to the second section walls. The section strips 3 a, 3 b, 3 c, 3 d may also be joined to the panel element 1 via the first section walls by means of an adhesive joint (FIG. 1).

Further, the section strips 3 a, 3 b, 3 c, 3 d contain third section walls which run parallel to the first section walls and, in contrast to the first section walls, are bent in the opposite direction away from the second section walls. FIG. 2 shows the second assembly step for production of a closure flap which is reinforced by a frame-type structure. The corner angles 32 a, 32 b, 32 c, 32 d (FIG. 2 b) are mounted on a panel element 31 (FIG. 2 a), brought into their predefined position with the help of positioning aids and adhesively bonded to the panel element. Subsequently, the section strips 33 a, 33 b, 33 c, 33 d are mounted on the panel element (FIG. 2 c) and aligned with respect to the corner angles 32 a, 32 b, 32 c, 32 d, and adhesively bonded with them to form a rectangular frame-type structure (FIG. 2 d).

FIG. 3 shows a panel element 40 made from a honeycomb sandwich composite. On both sides of a honeycomb-shaped core 41 are outer layers 42 a, 42 b which are adhesively bonded to the core layer. The outer layers 42 a, 42 b and the honeycomb core 41 are of aluminium or an aluminium alloy.

FIG. 4 shows a cross-section X-X through the closure flap in FIG. 1 in the region of the section part 3 c and the corner angle 2 c (see FIG. 1). As described above the section part 3 c contains a first section wall 6, a second section wall 12 and a third section wall 7. The corner angle 2 c is positioned on the panel surface by means of pin-shaped positioning aids 51. The first section wall of section part 3 c contains, on its free longitudinal edge which is directed towards the panel edge, a connecting means 50 for a hinge connection which projects out to a certain extent beyond the edge of the panel. The connecting means 50 contains a projection with one or more ring-shaped passages for inserting a hinge pin and connecting to a complementary structure for the purpose of creating a hinge connection to the vehicle structure (not shown here). 

1. Closure flap (11) comprising a flap element (1) and a reinforcing structure mounted on the flap element (1), the reinforcing structure comprises individual frame elements (2 a, 2 b, 2 c, 2 d, 3 a, 3 b, 3 c, 3 d) mounted on the flap element (1) which are attached to a frame-type structure.
 2. Closure flap according to claim 1, wherein the frame elements comprise corner elements (2 a, 2 b, 2 c, 2 d) and longitudinally running section parts (3 a, 3 b, 3 c, 3 d).
 3. Closure flap according to claim 2, wherein the corner elements (2 a, 2 b, 2 c, 2 d) are joined to the flap element (1) via an adhesive joint.
 4. Closure flap according to claim 2, wherein the section parts (3 a, 3 b, 3 c, 3 d) are connected via an adhesive joint to the corner elements (2 a, 2 b, 2 c, 2 d) and/or to the flap element (1).
 5. Closure flap according to claim 2, wherein the flap element (1) is made from a multi-layer panel material (40).
 6. Closure flap according to claim 2, wherein the flap element (1) comprises a composite panel (40), comprising a honeycomb-shaped core (41) having outer sheet layers (42 a, 2 b), joined to the core (41) by means of adhesive bonding.
 7. Closure flap according to claim 6, wherein the honeycomb shaped core (41) and/or one or both of outer sheets layers (42 a, 42 b) are of aluminium or an aluminium alloy.
 8. Closure flap according to claim 2, wherein the corner elements (2 a, 2 b, 2 c, 2 d) are corner angles having a U-shaped cross-section.
 9. Closure flap according to claim 6, wherein the section parts (3 a, 3 b, 3 c, 3 d) are angular section strips.
 10. Closure flap according to claim 9, wherein the section strips (3 a, 3 b, 3 c, 3 d) form at least two section walls, a first section wall (6) runs parallel to the section surface and makes contact with the panel surface, and a second section wall (12) lies at an angle to the first section wall (6) and projects from the panel surface.
 11. Closure flap according to claim 10, wherein the section strips (3 a, 3 b, 3 c, 3 d) form third section walls (7) which run parallel to the first section walls (6) and, with respect to the first section walls (6), are bent in the opposite direction from the second section walls (12), whereby the first and third section walls are joined via the second section walls to form a Z-shaped section.
 12. Closure flap according to claim 2, wherein the section parts (3 a, 3 b, 3 c, 3 d) and/or the corner elements (2 a, 2 b, 2 c, 2 d) are of aluminium or an aluminium alloy.
 13. Closure flap according to claim 2, wherein the corner elements (2 a, 2 b, 2 c, 2 d) and section parts (3 a, 3 b, 3 c, 3 d) are fitted together to make up a rectangular shaped frame-type structure, whereby a corner element (2 a, 2 b, 2 c, 2 d) is provided at each corner of the frame-type structure.
 14. Closure flap according to claim 13, wherein a wall of the section part (3 d) running parallel to the panel surface of the frame-type structure, forms a connecting structure for a torsional joint connection, in particular for a hinge.
 15. Process for manufacturing a closure flap according to claim 1, comprising the following steps: preparation of a flap element (1); mounting and positioning individual frame elements (2 a, 2 b, 2 c, 2 d) on the flap element; adhesively bonding the frame elements (2 a, 2 b, 2 c, 2 d) to the flap element (1) to make a frame-type structure.
 16. Process for manufacturing a closure flap according to claim 1, comprising the following steps: preparation of a flap element (1); mounting and positioning the corner elements (2 a, 2 b, 2 c, 2 d) on the flap element (1); adhesively bonding the corner elements (2 a, 2 b, 2 c, 2 d) to the flap element (1); mounting and positioning the section parts (3 a, 3 b, 3 c, 3 d) on the flap element (1); and adhesively bonding the section parts (3 a, 3 b, 3 c, 3 d) to the corner elements (2 a, 2 b, 2 c, 2 d) and/or the flap element (1).
 17. Process according to claim 16, wherein holes are provided in the flap element (1) to accommodate positioning aids for the purpose of positioning the corner elements (2 a, 2 b, 2 c, 2 d) on the flap element. (1).
 18. Process according to claim 17, including introducing positioning aids into the recesses in the flap element.
 19. Process according to claim 17, including providing positioning aids for positioning the corner elements (2 a, 2 b, 2 c, 2 d), in holes in the frame elements holes and in the flap element.
 20. Process according to claim 15, including adhesively bonding corner elements to the flap element (1).
 21. Process according to claim 16, comprising the additional steps of: mounting and positioning a reinforcing section (4) on the flap element (1); adhesively bonding the reinforcing section (4) to the flap element (1) and/or the section parts (3 a, 3 b, 3 c, 3 d).
 22. Process according to claim 21, including providing holes in the panel element and locating therein positioning aids for the purpose of positioning the reinforcing section (4).
 23. Process according to claim 22, including engaging the positioning aids for positioning the reinforcing section (4) in holes in the reinforcing section (4).
 24. Process according to claim 23, including adhesively bonding the reinforcing section (4) to the flap element (1). 